Building panels

ABSTRACT

A building or insulating panel ( 30 ) including a collapsible frame of generally square or rectangular configuration, which is collapsible between a generally flat condition and an erected condition in which it is installed. The frame including overlying top and bottom sheets ( 31,32 ) that are generally parallel and spaced apart in the erected condition of the frame by two webs ( 33,36 ) which are spaced apart to extend in generally parallel realationship lengthwise along opposite side regions of the frame. The webs ( 33, 36 ) extend substantially perpendicular to the top and bottom sheets ( 31, 32 ) in the erected condition and are disposed substantially parallel to the top and bottom sheets ( 31, 32 ) in the collapsed condition. The panel further includes reinforcing means ( 37 ) which is inserted between the top and bottom sheets ( 31, 32 ) when the frame is in the erected condition to reinforce the panel ( 30 ) against collapse. The insulating panel may have an intermediate sheet disposed between the top and bottom sheets which is adhesively connected to each of the top and bottom sheets. The intermediate sheet is formed as a corrugated sheet and at least one of the top and bottom sheets and the intermediate sheet are formed from reflective insulating foil to create a reflective air space.

[0001] The present invention relates to building panels and to a methodand arrangement of installing building panels. The present invention wasdeveloped in relation to insulating batts and particularly, although notexclusively, to the construction and installation of insulating battsformed from self-supporting sheets of reflective insulating material. Itwill therefore be convenient to describe the invention in relation tothat style of insulating batt, although it is to be appreciated, thatthe invention could apply to non-insulating panels and to insulatingbatts formed differently to or from alternative material to thatdescribed above.

[0002] Australian Patents Nos. 511853 and 647948 disclose insulatingbatts having substantially flat, self-supporting sheets of reflectiveinsulating material secured in substantially parallel, overlyingrelationship. The sheets of those batts are secured relative to eachother by parallel webs of sheet material that permit the batt to beadjusted between a collapsed condition to an erected condition.Advantageously, these batts have very little volume when collapsed andcan be stored and transported in that condition, for erection on sitewhen being installed generally in a roof of a building.

[0003] The installation of the above kinds of insulation batts is notalways simple, particularly in relation to commercial buildings, such aswarehouses and factories. In those buildings, it is preferable to fitthe insulating batts between adjacent purlins and until recently, asuitable method for such installation, which is both simple andeffective in respect of the insulation provided, has been unavailable.

[0004] According to the present invention there is provided a buildingpanel including a collapsible frame of generally square or rectangularconfiguration, which is collapsible between a generally flat condition,and an erected condition in which it is installed, said frame includingtop and bottom sheets that are generally parallel and spaced apart insaid erected condition of said frame by two webs which are spaced apartto extend in generally parallel relationship lengthwise along oppositeside regions of said frame, said webs extending substantiallyperpendicular to said top and bottom sheets in said erected conditionand being disposed substantially parallel to said top and bottom sheetsin said collapsed condition, said panel further including reinforcingmeans which is inserted between said top and bottom sheets when saidframe is in said erected condition to reinforce said panel againstcollapse.

[0005] The present invention further provides a method of installing abuilding panel having a collapsible frame of generally square orrectangular configuration, which is collapsible between a generally flatcondition, and an erected condition, said frame including top and bottomsheets that are generally parallel and spaced apart in said erectedcondition of said frame by two webs which are spaced apart to extend ingenerally parallel relationship lengthwise along opposite side regionsof said frame, said webs extending substantially perpendicular to saidtop and bottom sheets in said erected condition and being disposedsubstantially parallel to said top and bottom sheets in said collapsedcondition, said method including transporting said frame to aninstallation site in said collapsed condition, expanding said frame tosaid erected condition, inserting reinforcing means between said top andbottom layers of said frame and thereafter placing said panel inposition.

[0006] The reinforcing means can be of sheet form which is collapsiblebetween a substantially flat condition for transport and an erectedcondition for installation of the insulating batt, or it can be formedas a member ready for assembly in the frame in a nestable condition inwhich a plurality of reinforcing means can be nested together fortransport to the installation site. In either case, the advantages ofthe invention is realised by the compact nature of the reinforcing meansfor transport and production and the simple nature of the assemblyprocess. In either case, the reinforcing means is insertable in theerect condition thereof into the space of the erected frame, where afterthe insulating batt can be installed.

[0007] The invention advantageously is comprised of a collapsible frameand collapsible or nestable reinforcing means each of which can behandled and transported to the site of insulation with substantiallyreduced bulk compared to the erected condition of the panel or batt.Thus, the components of the insulating batt can be easily handled andtransported at minimum cost and are simple to erect and thereafter beinstalled. This compares with alternative batt structures which arebulky and more difficult to install.

[0008] The reinforcing means can be in the form of a corrugated sheetwhich includes successive oppositely facing peaks extending in contactwith each of the top and bottom sheets of the frame for supporting thosesheets in a spaced apart disposition. The corrugations could be of acurved configuration, taking a cross-sectional profile similar to a sinewave, or it may have a concertina-like or sawtooth profile which iscomprised of a plurality of substantially planar segments disposed atopposite inclined angles, so as to define a succession of adjacent peaksand troughs, with the apex of each peak and trough being in engagementwith either the top or bottom sheet of the frame. The strength of thepanel or batt when assembled relies partly on the frictional contactbetween the reinforcing means and the top and bottom sheets of theframe. Thus, a sine wave configuration provides better strength than thesawtooth profile, because the former has greater surface area contactthan the edge contact of the latter. An advantage of the presentinvention is that the reinforcing means need not be fixed within theframe, such as by an adhesive, but can be simply placed or inserted intothe frame. This provides for simple assembly which is a feature of thepresent invention.

[0009] The required spacing of the webs is dependent on the grade ofpaper normally used for construction of the panel or insulating batt.Thus, the use of a heavy paper grade can reduce the need for additionalwebs between the side edge webs. The reinforcing means and the webs bothcontribute to the stiffness of the panel or batt and the choice of thematerial of one can influence the material choice for the other.

[0010] It will be appreciated, that the above examples show that thereinforcing means could take a variety of forms. Thus, the form of thereinforcing means is not necessarily critical, but instead what isimportant, is that the reinforcing means be nestable or alternativelycollapsible, so that it may be transported to the insulation site eitherin a nested or substantially flat form so having the same transport andhandling advantages as the frame.

[0011] In one arrangement, the frame includes three or more websextending between the top and bottom sheets of the frame, so dividingthe space between the top and bottom sheets into two or more smallerspace segments. Therefore, the frame in this arrangement, includes apair of webs disposed toward opposite side edge regions of the frame andat least one further web disposed intermediate or midway between the twoedge webs. In a particularly preferred arrangement, a pair of webs aredisposed intermediate the side edge webs.

[0012] In the above arrangement, the reinforcing means is arranged toextend between adjacent webs. Thus, in the arrangement in which threewebs are disposed between the top and bottom sheets, the reinforcingmeans is comprised of two separate reinforcing members or components.Those members may be identical in profile or dissimilar as required.Alternatively, in the arrangement in which a pair of intermediate websis disposed between the side edge webs, three reinforcing members aredisposed between the top and bottom sheets of the frame.

[0013] In an alternative arrangement, reinforcing means may be disposedin only one of the space segments between adjacent frame webs. That is,in the arrangement in which two intermediate webs are disposed betweenthe side edge webs, thus defining three space segments, each of thosespace segments may accommodate reinforcing means, or alternatively onlyone or two of the space segments may accommodate such reinforcing means.The requirement for reinforcing means will depend on the rigidity of theinsulating batt which is required.

[0014] For example, in the above arrangement in which three spacesegments are formed, the insulating characteristics of the insulatingbatt may only require reinforcing means in one of the space segments,and that will facilitate a reduction in the overall cost of theinsulating batts. Alternatively, if the insulating batt has a length orwidth of such dimensions that require each of the space segments toaccommodate reinforcing means, then such means can easily be included.Therefore, the insulating batt of the invention is flexible in itsrequirement for reinforcing means, depending on the insulatingcharacteristics required, and the structural requirements.

[0015] A batt of the above described kind provides general advantages inrelation to storage and transport, because it can be stored and shippedin a collapsed form. It further provides advantages in production,because it is very easy to manufacture, assemble and install. The panelof the invention is particularly suited to installation in ceilings, inparticular so-called suspended T-bar ceilings generally found incommercial office space. The panel can replace presently used acousticor plasterboard tiles at a much lower cost. Additionally, the panel canbe formed as an insulating batt, which further enhances its use as aceiling panel.

[0016] The use of reflective insulating foil provides a particularadvantage of the present invention over acoustic and plasterboard panelsnow employed, in that reflective foil is waterproof. Accordingly,ceiling or wall leakage will not necessarily destroy or affect theperformance of the panel as it may with non-waterproof panels, whichinclude the aforementioned acoustic and plasterboard kind. Thisadvantage of the present invention extends to installation sites inregions of high humidity also, such that a panel of the invention,formed fully or partly from reflective insulating foil, may be preferredin such regions.

[0017] According to the present invention, there is further provided aninsulating batt having top and bottom sheets and an intermediate sheetwhich is disposed between the top and bottom sheets and which isadhesively connected to each of those sheets, the intermediate sheetbeing formed as a corrugated sheet and at least one of the top andbottom sheets and the intermediate sheet being from reflectiveinsulating foil, to create a reflective air space.

[0018] The above insulating batt can be manufactured by applying thecorrugated intermediate sheet adhesively to one of the top and bottomsheets and then adhesively applying the other of the top and bottomsheets to the intermediate sheet. Like the earlier described batt, thisbatt is simple to manufacture and install and, as it is envisaged thatit would having industry acceptable insulating characteristics in anoverall thickness of about 25 mm, it would also be attractive forstorage, transport and installation.

[0019] An insulating batt according the invention is suitable forinsulating a variety of structures, such as wall and roof structures.The insulating batts of the invention can be installed in a progressivemanner, by installing an insulating batt between adjacent purlins andpushing that batt along the length of the purlins with successive batts.The batts according to the invention can be fixed to the purlins in anysuitable manner or they may simply rest under their own weight withoutsagging, by employment of the reinforcing means.

[0020] The attached drawings show example embodiments of the inventionof the foregoing kind. The particularity of those drawings and theassociated description does not supersede the generality of thepreceding broad description of the invention.

[0021]FIG. 1 shows an insulating batt 30 which includes a frame havingtop and bottom layers 31 and 32 respectively which are generallyrectangular and disposed in parallel, overlying relationship. The topand bottom layers may be made of a double-sided foil laminate which inits planar form, is relatively flexible, although the invention is notrestricted to such a material and alternative materials may be employed.Materials such as those described in Australian patents 511833 and647948 are suitable for use in the construction of the insulating batt30.

[0022] The frame of the insulating batt 30 further comprises a pluralityof webs 33 to 36 which are disposed to extend lengthwise of the batt 30and substantially at right angles to the top and bottom layers 31 and32. The webs 33 to 36 can pivot relative to the top and bottom layers 31and 32, to permit the batt 30 to collapse from the erected conditionshown in FIG. 1 to a collapsed condition, in which the webs aresubstantially parallel to the layers 31 and 32. Thus, the webs areconnected to the top and bottom layers 31 and 32 in a manner to permitsuch pivoting movement and such an arrangement or construction isdisclosed in the aforementioned Australian patents. Therefore, thatconstruction can be employed in an insulating batt according to theinvention, or alternative constructions can be employed that permit thesame collapsible movement.

[0023] The insulating batt 30 of FIG. 1 includes four webs as shown.However, the invention is only required to include webs 33 and 36disposed along the side edges of the frame of the batt 30. Theintermediate webs 34 and 35 can be provided as required to suit thenecessary structural characteristics of the batt 30.

[0024] Between each of the webs illustrated in FIG. 1, is reinforcingmeans in the form of corrugated insulating sheet reinforcing components37 to 39. Each of the members 37 to 39 is formed with a plurality ofinclined planar sections as shown, which meet to form adjacentoppositely pointing apexes in contact respectively with the insidesurfaces of the top and bottom sheets 31 and 32. The reinforcing members37 to 39 also extend into contact with the webs 33 to 36. Thereinforcing members 37 to 39 support the frame of the insulating batt 30lengthwise against sagging. Thus, the batt 30 has considerable rigidityin the longitudinal direction L so that the batt 30 can be made to spangreater distances than would otherwise be possible without the members37 to 39. Additionally, the use of an insulating sheet as a medium forthe reinforcing members 37 to 39 facilitates better insulatingperformance than in absence of those sheets. Thus, the corrugatedinsulating reinforcing members 37 to 39 have a dual function.

[0025] The insulating batt 30 is advantageously collapsible, by removalof the corrugated reinforcing members 37 to 39 where after the frame ofthe batt 30 can be collapsed to a flat condition. The members 37 to 39can be nested together. Thus, at the site of installation, it is asimple matter of erecting the frame of the batt 30, and inserting thereinforcing members 37 to 39 into the space segments 40 to 42 betweenthe top and bottom layers 31 and 32, after which the batt is ready forinstallation.

[0026]FIG. 2 shows an alternative insulating batt 50 which has somecharacteristics of the insulating batt 30 of FIG. 1 and therefore likeparts will have the same reference numeral plus 100. The batt 50 howeverdiffers from the batt 30, by way of the addition of a second layer suchthat the batt 50 includes a bottom layer 132, and intermediate layer 51and a top layer 52. Such a batt can be manufactured according to themethods disclosed in Australian patent nos. 511853 and 647948. Thus, thebatt 50 includes webs 53 to 56 extending between the intermediate layer51 and the top layer 52. The webs 53 and 56 may be continuations of thewebs 133 to 136, although manufacturing limitations are likely torequire that the webs 54 and 55 be separately formed from the webs 134and 135.

[0027] In the arrangement shown in FIG. 2, reinforcing members 137, 138and 139 are disposed in the space segments 140, 141 and 142. Noreinforcing members are disposed in the spaces 56 to 58, although ifrequired reinforcing members could be inserted in these spaces. Thus,the insulating batt 50 illustrates the flexibility that the presentinvention provides. For example, if further reinforcement was required,reinforcing members could be included in only one of the space segments56 to 58, or in two or in each of those space segments. Thus, if theinsulating characteristics of the batt 50 were required to be higherthan that achievable by the arrangement illustrated in FIG. 2, then theaddition of further corrugated reinforcing members disposed in one ormore of the space segments 56, 57 and 58 may achieve those requirements.

[0028]FIG. 2 illustrates the flexibility that the present invention canprovide. The invention can therefore be applied for example, to a fourlayer insulating batt and the reinforcing members can be applied to eachor any selection of the space segments within the batt as consideredappropriate. The reinforcing members can be made of any suitablematerial and could for example be made of cardboard or stiff paper ifthe requirement of the reinforcing members was to provide rigidity onlyand little if no insulating characteristics. In the preferredarrangement however, the reinforcing members are constructed out of thesame material as the frame of the insulating batt so as to enhance theinsulating capability of each batt.

[0029] The invention described herein is susceptible to variations,modifications and/or additions other than those specifically describedand it is to be understood that the invention includes all suchvariations, modifications and/or additions which fall within the spiritand scope of the above description.

1. A building panel including a collapsible frame of generally square orrectangular configuration, which is collapsible between a generally flatcondition and an erected condition in which it is installed, said frameincluding overlying top and bottom sheets that are generally paralleland spaced apart in said erected condition of said frame by two webswhich are spaced apart to extend in generally parallel relationshiplengthwise along opposite side regions of said frame, said websextending substantially perpendicular to said top and bottom sheets insaid erected condition and being disposed substantially parallel to saidtop and bottom sheets in said collapsed condition, said panel furtherincluding reinforcing means which is inserted between said top andbottom sheets when said frame is in said erected condition to reinforcesaid panel against collapse.
 2. A panel according to claim 1, saidreinforcing means being of sheet form and being collapsible between agenerally flat condition and an erected condition, said reinforcingmeans being formed into said erected condition for insertion betweensaid top and bottom sheets of said frame.
 3. A panel according to claim1, said reinforcing means being formed as a member which is shaped readyfor insertion between said top and bottom sheets of said frame, saidshape of said reinforcing member being such as to permit nesting betweena plurality of said reinforcing members.
 4. A panel according to any oneof claims 1 to 3, said reinforcing means having a corrugated form forinsertion into said frame, said corrugated form defining successiveoppositely facing peaks respectively extending into contact with saidtop and bottom sheets of said frame.
 5. A panel according to claim 4,said corrugated form being of generally curved form.
 6. A panelaccording to claim 4, said corrugated form comprising a generallysawtooth profile.
 7. A panel according to any one of claims 4 to 6, saidreinforcing means being arranged to engage said webs.
 8. A panelaccording to any one of claims 1 to 7, said panel including at least afurther web disposed between said webs at said opposite side regions ofsaid frame and extending generally parallel thereto and substantiallyperpendicular to said top and bottom sheets in said erected condition ofsaid frame and being disposed substantially parallel to said top andbottom sheets in said collapsed condition of said frame, saidreinforcing means being provided between at least one pair of adjacentwebs.
 9. A panel according to claim 8, including a single further web.10. A panel according to claim 9, wherein said further web is disposedsubstantially midway between said webs at said opposite side regions.11. A panel according to claim 8, including a pair of further webs. 12.A panel according to any one of claims 1 to 11, said frame including anintermediate sheet disposed intermediate and substantially parallel tosaid top and bottom layers and having plan dimensions substantially thesame thereas and said webs being arranged to support said top and bottomsheets and said intermediate sheet in spaced apart relationship.
 13. Apanel according to any one of claims 1 to 12, said top and bottom sheetsand said webs being formed of cardboard or cardboard-like material. 14.A panel according to any one of claims 1 to 13, said panel being formedas an insulating batt, in which said top and bottom layers are formedfrom reflective insulating material.
 15. A panel according to claim 14,wherein said reinforcing means is formed from reflective insulatingmaterial.
 16. An insulating batt having top and bottom sheets, and anintermediate sheet disposed between the top and bottom sheets which isadhesively connected to each of said top and bottom sheets, saidintermediate sheet being formed as a corrugated sheet and at least oneof the top and bottom sheets and the intermediate sheet being formedfrom reflective insulating foil to create a reflective air space.
 17. Amethod of assembling a building panel having a collapsible frame ofgenerally square or rectangular configuration, which is collapsiblebetween a generally flat condition, and an erected condition, said frameincluding overlying top and bottom sheets that are generally paralleland spaced apart in said erected condition of said frame by two webswhich are spaced apart to extend in generally parallel relationshiplengthwise along opposite side regions of said frame, said websextending substantially perpendicular to said top and bottom sheets insaid erected condition and being disposed substantially parallel to saidtop and bottom sheets in said collapsed condition, said method includingexpanding said frame to said erected condition and inserting reinforcingmeans between said top and bottom layers of said frame.
 18. A method ofinstalling a building panel having a collapsible frame of generallysquare or rectangular configuration, which is collapsible between agenerally flat condition, and an erected condition, said frame includingoverlying top and bottom sheets that are generally parallel and spacedapart in said erected condition of said frame by two webs which arespaced apart to extend in generally parallel relationship lengthwisealong opposite side regions of said frame, said webs extendingsubstantially perpendicular to said top and bottom sheets in saiderected condition and being disposed substantially parallel to said topand bottom sheets in said collapsed condition, said method including asa first step, either of transporting said frame to an installation site,or expanding said frame to said erected condition and insertingreinforcing means between said top and bottom layers of said frame, thenconducting the other of these steps and thereafter placing said panel inan installed position.
 19. A method according to claim 18, wherein saidtransportation step is the first step conducted and for that step, saidframe is transported in said collapsed condition.
 20. A method accordingto claim 18 or 19, said reinforcing means being collapsible between agenerally flat condition and an erected condition, said method includingtransporting said reinforcing means in said flat condition to saidinstallation site and thereafter expanding said reinforcing means tosaid erected condition prior to insertion thereof into said frame.
 21. Amethod according to claim 18 or 19, said reinforcing means being formedas a member which is nestable with other reinforcing members and saidmethod including transporting a plurality of said reinforcing members tosaid installation site in a nested condition.
 22. A method according toany one of claims 18 to 21, said panel being an insulating batt.